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DIFFERENTIAL CASE INSPECTION

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  1. Click here

    INSPECT FRONT DIFFERENTIAL


    1. A017DUYE01

      Using a dial indicator, measure the backlash of one pinion gear while holding the front differential side gear toward the case.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)
      Note:

      Do not mount the surface of the front differential case which contacts with the bushing in a vise.

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Table 1. Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)
    2. A017C2YE02

      Engage the front differential side to the above mentioned front differential case.

    3. Install the differential case LH to the front differential case and measure its center.

    4. After that, remove the differential case LH.

    5. A017FA8E01

      Using a straightedge and feeler gauge, measure the clearance between the front differential case and the front differential side gear.

      Tip:

      • t= Thrust washer thickness

      • L= Clearance

      • t= L-0.162 to 0.265 mm (0.0064 to 0.0104 in.)

      If the clearance is not within the specified range, refer to the table below and select a thrust washer so that the clearance is within the specified range.

      Table 2. Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      A 0.95 (0.0373) F 1.20 (0.0472)
      B 1.00 (0.0393) G 1.25 (0.0492)
      C 1.05 (0.0413) H 1.30 (0.0512)
      D 1.10 (0.0433) J 1.35 (0.0532)
      E 1.15 (0.0453) K 1.40 (0.0552)

      If the clearance is not within the specified range, parts may have been assembled incorrectly, so check and reassemble it.

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    INSPECT CENTER DIFFERENTIAL


    1. A017E9IE01

      Pressing and holding the differential spider toward the differential case RH, measure the pinion's backlash with a dial indicator as illustrated.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Table 3. Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    2. A017EF2E01

      Temporarily install the No. 2 differential side gear thrust washer LH, center differential side gear conical spring washer, and No. 2 differential case to the differential case LH.

      Tip:

      Ensure that the conical washers are installed correctly.

    3. A017DGTE01

      Install the differential intermediate case to the differential case and secure the assembled parts with the 4 bolts.

    4. A017DXHE01

      Remove the differential spider, 5 center differential pinions, and 5 center differential pinion thrust washers from the differential case RH. Put them in the differential intermediate case and secure the case.

    5. A017CR6E01

      Pressing and holding the differential spider toward the differential intermediate case, measure the pinion's backlash with a dial indicator.

      Standard backlash
      0.05 to 0.20 mm (0.0020 to 0.0079 in.)

      If the backlash is not within the specified range, refer to the table below and select a thrust washer so that the backlash is within the specified range.

      Table 4. Thrust washer thickness: mm (in.)
      Mark Thickness Mark Thickness
      MA 0.80 (0.0313) MH 1.15 (0.0453)
      MB 0.85 (0.0333) MJ 1.20 (0.0472)
      MC 0.90 (0.0353) MK 1.25 (0.0492)
      MD 0.95 (0.0373) ML 1.30 (0.0512)
      ME 1.00 (0.0393) MM 1.35 (0.0532)
      MF 1.05 (0.0413) MN 1.40 (0.0552)
      MG 1.10 (0.0433) - -
    6. A017BWAE01

      Remove the 4 bolts and disconnect the differential case LH from the differential intermediate case.

    7. A017EBNE02

      Remove the No. 2 differential case from the differential case LH.

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    ADJUST TAPERED ROLLER BEARING PRELOAD


    1. A017CZKE01

      Install the intermediate case to the differential case LH and secure them with the 4 bolts.

    2. Install the differential assembly to the transaxle case.

    3. A017BQUE04

      Clean the matching surfaces of the transaxle case and transaxle housing.

    4. Install the transaxle housing to the transaxle case and tighten them with the 16 bolts.

      Bolt A
      25 N*m 255 kgf*cm 18 ft.*lbf
      Bolt B
      33 N*m 337 kgf*cm 24 ft.*lbf
      Bolt C
      29 N*m 295 kgf*cm 21 ft.*lbf
      Bolt D
      28 N*m 286 kgf*cm 21 ft.*lbf
      Tip:

      Apply adhesive or equivalent to bolts A and D

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Bolt length
      Bolt A, B
      50 mm (1.969 in.)
      Bolt C
      42 mm (1.654 in.)
      Bolt D
      72mm (2.835 in.)
      Note:

      Apply adhesive to the bolts and tighten them within 10 minutes of application

      Tip:

      Bolt A is a non-reusable bolt. However, bolt A can be used after cleaning it.

    5. A017GAYE02

      Using SST, turn the differential assembly right and left 2 or 3 times to allow the bearing to settle.

      09564-32011

    6. Using SST and a torque wrench, measure the turning torque of the differential case assembly.

      09564-32011
      New bearing (*)
      0.2 to 0.69 N*m 2.0 to 7.0 kgf*cm 1.8 to 6.1 in.*lbf
      Used bearing (*)
      0.10 to 0.35 N*m 1.0 to 3.6 kgf*cm 0.9 to 3.1 in.*lbf
      Tip:

      • (*): Turning torque at 60 rpm

      • If the turning torque is not within the specified range, refer to the table below and select a thrust washer so that the turning torque is within the specified range.

      Table 5. Flange thickness: mm (in.)
      Mark Thickness Mark Thickness
      0 2.000 (0.0787) 9 2.450 (0.0965)
      j 2.025 (0.0797) T 2.475 (0.0974)
      1 2.050 (0.0807) A 2.500 (0.0984)
      K 2.075 (0.0817) U 2.525 (0.0994)
      2 2.100 (0.0827) B 2.550 (0.1004)
      L 2.125 (0.0837) V 2.575 (0.1014)
      3 2.150 (0.0846) C 2.600 (0.1024)
      M 2.175 (0.0857) W 2.625 (0.1034)
      4 2.200 (0.0866) D 2.650 (0.1043)
      N 2.225 (0.0876) X 2.675 (0.1053)
      5 2.250 (0.0886) E 2.700 (0.1063)
      P 2.275 (0.0896) Y 2.725 (0.1073)
      6 2.300 (0.0906) F 2.750 (0.1083)
      Q 2.325 (0.0915) AA 2.775 (0.1093)
      7 2.350 (0.0925) G 2.800 (0.1102)
      R 2.375 (0.0935) AB 2.825 (0.1112)
      8 2.400 (0.0945) H 2.850 (0.1122)
      S 2.425 (0.0954) - -
    7. A017F8ME01

      Remove the 16 bolts and the transaxle housing.

    8. A017CZKE02

      Remove the differential assembly.